Installation & Servicing Instructions Baxi 50 HE Plus Baxi 80 HE Plus Baxi 100/2 HE Plus Wall Mounted Powered Flue Condensing Boilers Gas Fired Central Heating Units These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping © Baxi Heating UK Ltd 2006
Natural Gas Building Regulations and the Benchmark Commissioning Checklist Baxi 50 HE Plus G.C.No 41 077 41 Baxi 80 HE Plus G.C.No 41 077 42 Baxi 100/2 HE Plus G.C.No 41 075 34 Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Self Certification Scheme Building Control Install and Commission this appliance to manufacturer's instructions Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Building Control Scheme on member's beha
Legislation IMPORTANT - Installation, Commissioning, Service & Repair This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance. In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations.
Safe Manual Handling General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE. There is no ‘safe’ limit for one man - each person has different capabilities.
Contents Section 6 © Baxi Heating UK Ltd 2006 Page 1.0 Introduction 7 2.0 General Layout 8 3.0 Appliance Operation 9 4.0 Technical Data 10 5.0 Dimensions and Fixings 11 6.0 System Details 12 7.0 Site Requirements 16 8.0 Installation 23 9.0 Electrical 29 10.0 Commissioning the Boiler 31 11.0 Fitting the Outer Case 32 12.0 Servicing the Boiler 33 13.0 Changing Components 35 14.0 Short Parts List 42 15.
1.0 Introduction 1.1 Description 1. The Baxi 50 HE Plus, 80 HE Plus and100/2 HE Plus are gas fired room sealed fan assisted condensing central heating boilers. 2. The maximum output of the Baxi 50 HE Plus is 52,000 Btu/hr. The maximum out put of the 80 HE Plus is 75,000 Btu/hr. The maximum output of the Baxi 100/2 HE Plus is preset at 75,000 Btu/hr but can be set to 100,000 Btu/hr (see section 8.8). All three boilers automatically adjust their outputs down to 30,000 Btu/hr according to the system load.
2.0 General Layout 2.1 16 1 Fig. 5 15 14 2 3 Layout (Figs. 3,4,5 & 6) 1. Wall Plate 2. Flue Elbow 3. Heat Exchanger 4. Burner 5. Air Box 6. Fan Protection Thermostat 7. Fan Assembly 8. Condensate Trap 9. PCB Housing Assembly 10. Gas Tap 11. Gas / Air Ratio Valve 12. Flow Pipe Connection 13. Return Pipe Connection 14. Flow Temperature Safety Thermostat - Black 15. Flow Temperature Thermistor - Red 16. Flow Switch (dry fire protection) 13 2.
Mains On. 3.0 Appliance Operation 3.1 Flow temperature less than set point ? NO 1. Switched Live On: When the switched live switches on if the flow temperature is less than the set point then pump overrun occurs. When the switched live switches on if the flow temperature is greater than the set point then pump overrun occurs. YES 10 second Pump On. 2. Pump On: The pump is on while the fan, spark generator and gas valve are off. After 10 seconds if the flow switch has made then fan pre-purge occurs.
4.0 Technical Data Appliance Type C13 Appliance Category C33 CAT I 2H Injector (Natural Gas) 6.5mm Diameter CO/CO2 Ratio Up to a maximum of 0.004 Heat Input (Q)(Gross) Max Min 50 HE Plus 16.88 57,600 10.2 34,840 CO Level 9% ± 1% Nox Class 5 kW Btu/hr 80 HE Plus kW Btu/hr 24.50 83,600 10.2 34,840 100/2 HE Plus (see note) kW Btu/hr 33.76 115,200 10.2 34,840 Heat Output (P) (Non Condensing 70° C Mean Water Temp) Max Min 50 HE Plus kW Btu/hr 15.24 52,000 9.
5.0 Dimensions and Fixings DIMENSIONS A 600mm E 3° (1 in 20) B 320mm C 390mm A D 125mm Ø Min. E 150mm F 125mm B 360° Orientation C D Tube Ø 110mm The 3° (1 in 20) fall provided by the elbow is to allow condensate to run back to the boiler, for disposal through the condensate discharge pipe. Fig.
6.0 System Details 6.1 Water Circulating Systems 1. The appliance is suitable for use with open vent fully pumped systems and sealed systems . The following conditions should be observed on all systems: • The static head must not exceed 30m (100ft) of water. • The boiler must not be used with a direct cylinder. • Drain cocks should be fitted to all system low points. • All gas and water pipes and electrical wiring must be installed in a way which would not restrict the servicing of the boiler.
6.0 System Details Copper 0.5m Copper 0.5m Flow Boiler 6.3 Return Copper 1m 1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system. The connections to the boiler will accept 22mm pipe. Fig. 9 mm 500 45° 1000mm Min Pipework 2. A 20 °C (36°F) drop in temperature across the system is recommended for condensing boilers.
Key to colours b br w o gr g/y 230V 50Hz L N E Y Plan Diverter Valve b g/y w Cylinder Stat gr 1 Room Stat o C 2 Boiler L E N P/F - Blue Brown White Orange Grey Green/Yellow 6.0 System Details 6.6 System Controls This boiler does not require a bypass. This boiler does not require a permanent live. The pump only needs wiring directly to the boiler for fully TRV’d systems. 1.
6.0 System Details 3 Litre Top Up Bottle (if required) Air Vent Safety Valve Filling Point Pressure Gauge Pump Radiator Circuit Expansion Vessel System Drains at Low Point Max Boiler Flow Temp = 82° C Method of determining minimum valve of expansion vessel volume for sealed systems using Baxi Boilers Vessel Charge Pressure (Bar) Initial System Pressure (Bar) Multiply Total Water Content Of System By (Litres) 0.5 0.5 1.0 1.5 2.0 0.067 0.112 0.207 0.441 1.0 1.5 2.0 0.087 0.152 0.330 1.5 2.
7.0 Site Requirements 7.1 Location NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply.
390mm 5mm Min 5mm Min 7.0 Site Requirements 7.3 Clearances (Figs. 15 &16) 200mm 1. A flat vertical area is required for the installation of the boiler. 2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler. 600mm 3. For unventilated compartments see Section 7.2. 7.4 Gas Supply 1.
Termination to an internal soil and vent pipe 7.0 Site Requirements 7.6 Boiler Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER 50mm per me tre of 2.5° M inimum The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run. pipe ru n fall NOTE: It is unnecessary to fit an air break in the discharge pipe.
7.0 Site Requirements Terminal Position with Minimum Distance (Fig. 17) (mm) Aa Directly below an opening, air brick, opening windows, etc. 300 Ba Above an opening, air brick, opening window etc. 300 Ca Horizontally to an opening, air brick, opening window etc. 300 D Below gutters, soil pipes or drain pipes. 25 E Below eaves. 25 F Below balconies or car port roof. 25 G From a vertical drain pipe or soil pipe. 25 (i) 25 (ii) 115 H From an internal (i) or external (ii) corner.
A - Standard Flue 7.0 Site Requirements 7.8 D Q Flue options Concentric The maximum equivalent lengths are 4m (horizontal) or (vertical). There lengths exclude the standard elbow and flue/terminal assembly (horizontal) and terminal assembly (vertical). Twin Flue The total maximum equivalent flue length is 150m. NOTE: Each 1m of flue duct should be calculated as 2m. E Any additional “in line” bends in the flue system must be taken into consideration.
30 7.0 Site Requirements 50 28 7.9 &8 26 NOTE: Please read this section in conjunction with the instructions supplied in the kit. The table opposite supplements information in the kit literature. 0 24 22 0/2 10 20 70Ø Exhaust (metres) X 18 Plume Displacement Kit 1. This kit is recommended for installations where the condensate plume emitted from the flue may cause a nuisance or affect the surroundings. 2. The flue consists of two main parts.
7.0 Site Requirements 7.10 Flue Dimensions See Section 2.2. The standard horizontal flue kit allows for flue lengths between 270mm (105/8”) and 800mm (32”) from elbow to terminal (Fig. 18). m 0m 80 m 0m 27 The maximum permissible equivalent flue length is: 4 metres (Fig. 18a). NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg. 45° = 0.5m, 90° = 2 x 45° = 1m etc. 7.11 Terminal Guard (Fig. 19) 1.
8.0 Installation Edge of Boiler Example 2m 125mm Check Site Requirements (section 7) before commencing. Example V = 110mm EXAMPLE: Boiler is 2 metres away from corner of wall, flue duct hole is 110mm up from horizontal side flue centre line. This will maintain the approx 3° backfall to the boiler. Horizontal Side Flue Centre Line Centre Hole Wall Thickness Flue Hole ø up to 227mm 125mm core drill up to 750mm 150mm core drill up to 1200mm 175mm core drill Wall Plate Template 8.
8.0 Installation 8.2 Preparing The Boiler Lower Door Panel 1. Remove the outer carton. 2. Remove the internal packaging. 3. Lift the outercase upwards and remove (Fig. 23). Outercase Break Off Upper & Lower Pipe Run Options Fig.
8.0 Installation 8.3 Retaining Bracket Fitting The Boiler (Fig. 24) 1. Remove the screw and retaining bracket from the wall plate spring clip. 2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate. (See Safe Manual Handling page 5.
8.0 Installation Wall Thickness 8.6 Making the Gas Connection 1. Connect the gas supply to the G1/2 (1/2in BSPT Internal) gas tap. This is located on the lower right side of the boiler, access by hinging down the PCB housing (see Fig. 32). 3° (1 in 20) 8.7 Fitting The Flue Before fitting the flue, check the condensate drain integrity (see section 8.5). IMPORTANT: The flue should always be installed with a 3° (1 in 20) fall from terminal to elbow, to allow condensate to run back to the boiler.
8.0 Installation 8.7 Inner Flue Support Bracket Fitting the Flue (Cont) 6. Ensure the inner flue support bracket is positioned in the flue (Fig. 28). 7. Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown (Fig. 29). Fig. 28 8. Place the gasket over the flue exit on the boiler. 9. Slide the flue assembly through the hole in the wall. Flue 10. Engage the elbow on to the flue connection on top of the boiler.
8.0 Installation 8.8 Making The Electrical Connections WARNING: This appliance must be earthed 1. The electrical connections are on the right hand side of the unit. 2. Undo the two screws securing the cable clamp and place to one side (Fig. 31). 3. The Baxi 100/2 HE Plus is factory set to give a maximum output of 22.0 kW (75,000 Btu/hr).
9.0 Electrical 9.
9.0 Electrical 9.
10.0 10.1 Commissioning the Boiler Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Flush the whole system using a suitable flushing agent (see Section 6.2) and vent the radiators. Check for water leaks. 3. Refill the system with inhibitor following the inhibitor manufacturer’s instructions and BS 7593 Code of Practice for Treatment of Water in Domestic Hot Water Central Heating Systems (see Section 6.2). 4.
11.0 11.1 Fitting the Outer Case Fitting The Outer Case Break Off Panel 1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate. Break off top or bottom panel as required to accommodate pipework runs (Fig.37). 2. Using the two screws supplied in the kit, secure the outercase to the combustion box (Fig. 37). 3. Replace the lower front door panel (Fig. 38). 4.
12.0 12.1 Servicing the Boiler Annual Servicing IMPORTANT: When servicing ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. “The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.” Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended.
12.0 12.1 Servicing the Boiler Annual Servicing (Cont) Flue Sampling Point 10. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42). Fig. 41a b) Loosen the screw retaining the gas injector pipe at the venturi (Fig. 42). c) Undo the two wing nuts to disconnect the fan (Fig. 42). d) Remove the fan and disconnect the electrical supply to it (Fig. 42).
13.0 13.1 Changing Components Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. “The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.” Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended.
13.0 13.3 Changing Components Flowswitch (Fig. 47) 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). 2. Remove the two screws on the support bracket. 3. Remove the clip securing the flow pipe to the flowswitch. Support Bracket 4. Disconnect the inline electrical connection. 5. Pull pipe away from flowswitch. 6. Remove the two screws securing the flowswitch to the boiler. 7. Remove the flowswitch. Flow Switch 8. Fit the new flowswitch and reassemble in reverse order. Flow Pipe 9.
13.0 13.4 Control Knob Changing Components PCB (Figs. 48 & 49) WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access. 1. Pull the control knob off the spindle and remove the plastic button cover. Refit them onto the new PCB (Fig. 48). Plastic Button Cover 1. Remove the top right hand securing screw and hinge down the PCB housing and disconnect the electrical connections noting their positions NOTE: Check the PCB for the presence of input jumpers - see section 8.8.
13.0 Changing Components The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel. 1. Remove the airbox door panel by loosening the four 1 /4 turn screws (Fig. 50). 13.5 Spark and Sensing Electrodes (Fig. 51) 1. Disconnect all three leads from tabs. Spark Opaque cable Earth Green/Yellow cable Sensing White cable 2.
13.0 Changing Components The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.6). 13.7 Injector Pipe (Fig. 53) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve. 2. Fit the new injector pipe and reassemble in reverse order. 13.8 Injector Pipe Gas Valve (Fig. 53) 1. Remove the Control PCB (see Section 13.4). 2. Isolate gas supply and disconnect the gas tap by removing the four screws.
13.0 Combustion Box Door Panel Changing Components The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.6 and 13.10). 1. Remove the combustion box door by removing the four securing screws (Fig. 55). IMPORTANT: On refitting the combustion box door check the condition of the combustion box door seals. 13.10 Fig. 55 Support Bracket Burner Burner (Fig. 56) 1.
13.0 13.12 Changing Components Heat Exchanger Lower Insulation Pad (Fig. 60) 1. Remove all components in the base of the airbox. 2. Remove the burner (see section 13.10). 3. Remove the four bolts securing the combustion box base. 4. Remove the combustion box base. 5. Pull the central insulation panel down from the centre of the heat exchanger and remove the lower insulation pad. Central Insulation Panel Upper Insulation Pad 6. Fit the new insulation pad and reassemble in reverse order.
14.0 Short Parts List Short Parts List A B C Key No. G.C. No. Description A E06 058 Flow Temperature Manufacturers Part No.
15.0 High Fault Finding Reset NOTE: The fan is supplied with 325 Vdc. Low Fan Fault Finding should only be carried out after the boiler has been electrically isolated. ON Lockout Boiler On Mains On LED Light (Red) LED Light (Green) LED Light (Green) Lights Off Off Off YES General Fault Finding should only be carried out by someone who is appropriately qualified. Go to Electrical Supply section of the fault finding instructions.
Lights Off Off Off ELECTRICAL SUPPLY 15.0 Fault Finding ON NO 240V at A ? No Switched Live to boiler. Check Systems Controls and System Wiring. YES NO 240V at B ? A Check wiring from terminal block to PCB. YES L NO PCB fuse OK ? Check for shorts on pump, fan & gas valve. Replace if shorted & replace fuse. YES Replace PCB.
Lights On Flash Flash 15.0 Fault Finding DRY-FIRE ON Are Flow & Return reversed ? NO Swop Flow & Return. E Is the system full of water ? NO Fill system with water and bleed out all air. L N Optional Pump Replace PCB. Live YES YES Turn mains off & on. After 5 sec, is there 240V at E? NO Is the pump running ? YES YES Unplug 5-way PCB connector. Is there continuity between H (run pump from switched live) ? NO Turn mains off, unplug 7-way connector to PCB.
Lights On Off On IGNITION LOCKOUT 15.0 Fault Finding ON I NO Is there gas at gas valve inlet ? Check isolation valve and gas supply. J 5-way Connector YES Remove 5-way connector from gas valve. Is there 240 Vdc between I & J during ignition ? NO Reset Lockout. Is there gas flow (check at meter) ? YES Replace Gas Valve. NO YES Is there at least 18mbar dynamic at gas valve inlet ? NO Remove the larger or the two 6-way PCB connectors.
Lights Flash Off On OVERHEAT LOCKOUT 15.0 Fault Finding ON Disconnect black stat on flow pipe. When flow < 60° C is there continuity across stat ? NO Replace Stat. YES Reconnect stat. Disconnect fan stat. When fan temp < 60° C is there continuity across stat ? NO Replace Stat. YES Reconnect stat. Disconnect the larger of the 6-way PCB connectors. Is there continuity across M ? NO YES Disconnect thermistor (red sensor on flow pipe). Is resistance between 0.
Lights Flash Flash On FAN LOCKOUT 15.0 Fault Finding NOTE: The fan is supplied with 325 Vdc. ON Fan Fault Finding should only be carried out after the boiler has been electrically isolated. Fan Connection Unplug 3-way PCB connector & unplug fan. Is there continuity from N to O & from P to Q ? PCB Connection NO Rectify wiring. O N Q P YES Unplug the smaller of the 6-way PCB connector. Is there continuity from R to S & from T to U & from V to W ? YES Replace fan.
Lights On Flash On THERMISTOR 15.0 Fault Finding ON Unplug thermistor, Is thermistor resistance between 0.5kΩ & 20kΩ ? NO Replace thermistor. D YES Plug in thermistor, leave 8-way connector unplugged. Is resistance at D between 0.5kΩ & 20kΩ ? NO Wiring from PCB to thermistor faulty. Viewed from Wire Entry end YES Replace PCB.
BENCHMARK No. 5 1 1 3 6 3 8 GAS BOILER COMMISSIONING CHECKLIST COLLECTIVE MARK BOILER SERIAL No. NOTIFICATION No.
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No.
All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request. BAXI A Tr a din g D i v i s i o n of B a x i Heat i ng U K Lt d Brooks House, Coventry Road, Warwick.
